Hydrogen supplemental system for on-demand hydrogen generation for internal combustion engines

ABSTRACT

A hydrogen generation system for producing hydrogen and injecting the hydrogen as a fuel supplement into the air intake of internal combustion engines. Hydrogen and oxygen is produced with a fuel cell at low temperatures and pressure from water in a supply tank. The hydrogen is directed to the air intake of the engine while the oxygen is vented to the atmosphere. The device is powered by the vehicle battery. The system utilizes an engine sensor that permits power to the system only when the engine is in operation.

CROSS-REFERENCES

This is a continuation application of U.S. application Ser. No.13/224,338, filed Sep. 2, 2011 which is a continuation-in-partapplication of U.S. application Ser. No. 12/790,398, filed May 28, 2010,the contents of which are incorporated herein by reference.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to hydrogen generation devices. Moreparticularly, the present invention relates to a hydrogen supplementalsystem that can be used with internal combustion engines for increasedfuel efficiency and reduced carbon emissions.

2. Description of the Related Art

There are a number of devices on the market that create HHO gas,otherwise known as Brown's gas, which is used as a supplement togasoline and diesel engines. HHO gas consists of two parts hydrogen toone part oxygen. These devices typically comprise an electrolyzer whichdecomposes water into hydrogen and oxygen. An example is U.S. Pat. No.4,023,405. These electrolyzers typically use an electrolyte, mostnotably KOH, Potassium hydroxide, or baking soda. A voltage is placedacross the device to produce the HHO gas.

The main problem with most of these devices is that the energy requiredto produce the hydrogen creates a substantial load on the electricalsystem of the vehicle. Similar to running the air conditioner in anyvehicle, the additional electrical load causes the miles per gallons tobe reduced. Even though the hydrogen typically boosts the efficiency andmiles per gallon of the vehicle, the additional electrical load on thevehicle to create the hydrogen is usually great enough to minimize or inmany cases negate most or all of mileage gains of the vehicle.

Also, most HHO systems produce the hydrogen and oxygen in a combined gasstream. The hydrogen and oxygen gases are not generally separated fromeach other. In the case of modern gasoline powered vehicles, this extraoxygen is detected by the vehicle's oxygen sensors which communicatethis extra oxygen level to an on-board computer, namely and ElectronicControl Unit ECU of the vehicle. When the ECU detects this extra oxygen,it is a signal that the engine is running lean and the ECU adds moregasoline to the engine. This also negates most of the fuel efficiencygains.

Furthermore, HHO systems generally use either baking soda or PotassiumHydroxide KOH. KOH is generally preferred over baking soda because ofits stability and because it causes less deterioration of stainlesssteel plates or other plates used in the electrolyzer. However, KOH hasto be handled with care because it is caustic, and the crystals can bedangerous if not handled properly. The electrolyte normally has to beinserted into the unit at the proper proportions for optimum operationof the electrolyzer. Extreme care must be taken when using it. It is notthe type of product you would generally like to put in the hands of aninexperienced consumer.

Complex installation is another issue with typical HHO systems. Spaceusually has to be found somewhere in the engine compartment or outsidethe vehicle. Since all vehicles are different, finding a suitable spotunder the hood to install the device in many vehicles is next toimpossible. Also, the systems are typically connected into theelectrical systems of the vehicles which can cause blown fuses and ahost of other problems if not installed properly. Hydrogen is onlyneeded when the vehicle is actually running, not when the ignition isturned on. During the installation, care must be observed to make surethe electrical power is provided to the device only when the engine isrunning. Otherwise there can be hydrogen accumulation in the air intake.This further complicates the installation of these systems.

SUMMARY OF THE INVENTION

The present invention relates to a portable and compact, on-demandhydrogen supplemental system for producing hydrogen gas and injectingthe hydrogen gas into the air intake of internal combustion engines,particularly for vehicles. Hydrogen and oxygen is produced by a fuelcell at low temperatures and pressure from water in a supply tank. Thehydrogen gas and oxygen gas is passed back thru the supply tank fordistribution and water preservation. The gases are kept separate by adivider in the tank and the water level in the tank. In the case ofgasoline engines, the hydrogen gas is directed to the air intake of theengine while the oxygen gas is optionally vented to the atmosphere. Thedevice can be powered by the vehicles alternator, a stand alone battery,waste heat or solar energy. The system utilizes a vacuum switch or otherengine sensor that regulates power to the system and therefore hydrogenproduction for the engine only occurs when the engine is running.Therefore as the hydrogen is produced it is immediately consumed by theengine. No hydrogen is stored on, in or around the vehicle.

BRIEF DESCRIPTION OF THE DRAWINGS

The foregoing and a better understanding of the present invention willbecome apparent from the following detailed description of exampleembodiments and the claims when read in connection with the accompanyingdrawings, all forming a part of the disclosure of this invention. Whilethe foregoing and following written and illustrated disclosure focuseson disclosing example embodiments of the invention, it should be clearlyunderstood that the same is by way of illustration and example only andthe invention is not limited thereto, wherein in the following briefdescription of the drawings:

FIG. 1 is a detailed drawing of a portable hydrogen supplemental systemshowing a water tank and housing design according to the presentinvention.

FIG. 2 is a schematic showing a portable hydrogen supplemental systeminstalled in a typical vehicle according to the present invention.

FIG. 3 is a diagram illustrating the operation and details of a PEMelectrolyzer according to the present invention.

FIG. 4 is a diagram of another embodiment of the water tank 6 accordingto the present invention.

FIGS. 5A-B are diagrams of another embodiment of a mounting bracket 3according to the present invention.

FIG. 6 is a diagram of an embodiment of the control circuit 50 accordingto the present invention.

DETAILED DESCRIPTION OF THE INVENTION

The present invention as will be described in greater detail belowprovides an apparatus, method and system, particularly, for example, ahydrogen supplemental system used to increase the fuel efficiency andreduce carbon emissions for internal combustion engines. The presentinvention provides various embodiments as described below. However itshould be noted that the present invention is not limited to theembodiments described herein, but could extend to other embodiments aswould be known or as would become known to those skilled in the art.

The present invention as shown in FIG. 1 provides a portable hydrogensupplemental system 1 which includes a housing unit 2 that can besecured in the trunk or other flat surface of a vehicle by mountingbracket 3 and fastening units 4. Inside the housing unit 2 are a fuelcell 5 and a water tank 6 positioned above the fuel cell 5 arranged insuch a manner as to supply water 7 to the fuel cell by gravity. Thewater tank 6 is supported in the housing unit 2 above the fuel cell bysupporting means 8. The housing unit 2 is designed to be readilyremovable from the mounting bracket 3.

The water tank 6 includes a water supply fitting 9 positioned on theunderside thereof connected to a tube or other supply means 10 that isin turn connected to water inlet fitting 11 on the fuel cell 5. Water issupplied to the fuel cell 5 by the supply means 10. The fuel cell 5 alsoincludes hydrogen gas outlet fittings 12 and oxygen gas outlet fitting13 which are connected by tubes or additional supply means 14 and 15 togas inlet fittings 16 on the underside of the water tank 6. The watertank 6 includes at least one divider 17 that divides the tank 6 into atleast two sections, a hydrogen section 18 and an oxygen section 19. Thedivider 17 is formed along the inner wall of the tank 6 and extends toapproximately ¼″ from the bottom surface 20 of the tank 6. The tank 6includes a fill spout 21 which permits the tank to be filled with water.As water is placed into the tank 6, the tank fills evenly on both sidesof the divider 17.

The fuel cell 5, which is commonly known to produce electricity, isoperated in reverse to produce hydrogen and oxygen gases. Water fillsthe fuel cell from the water tank and when a voltage is placed acrossthe cell, hydrogen and oxygen gases are produced.

According to the invention the fuel cell 5 can, for example, be a protonexchange membrane or polymer electrolyte membrane (PEM) electrolyzer. APEM electrolyzer includes a semipermeable membrane generally made fromionomers and designed to conduct protons while being impermeable togases such as oxygen or hydrogen. This is their essential function whenincorporated into a membrane electrode assembly (MEA) of a protonexchange membrane fuel cell or of a proton exchange membraneelectrolyzer: separation of reactants and transport of protons.

As known an electrolyzer is a device that generates hydrogen and oxygenfrom water through the application of electricity and includes a seriesof plates through which water flows while low voltage direct current isapplied. Electrolyzers split the water into hydrogen and oxygen gases bythe passage of electricity, normally by breaking down compounds intoelements or simpler products.

A PEM electrolyzer is shown in FIG. 3. The PEM electrolyzer includes aplurality of layers including external electrodes 41 disposed oppositeto each other one of which is the anode 41 a and the other of which isthe cathode 41 b, electrocatalysts 42 a and 42 b disposed respectivelyon the anode 41 a and the cathode 41 b, and a membrane 43 disposedbetween the electrocatalysts 42 a and 42 b. The PEM electrolyzer furtherincludes an external circuit 44 which applies electrical power to theanode 41 a and the cathode 41 b in a manner such that electricity powerin the form of electrons flow from the anode 41 a, along the externalcircuit 44, to the cathode 41 b and protons are caused to flow throughthe membrane 43 from the anode 41 a to the cathode 41 b.

The efficiency of a PEM electrolyzer is a function primarily of itsmembrane and electro-catalyst performance. The membrane 43 includes asolid fluoropolymer which has been chemically altered in part to containsulphonic acid groups, SO₃H, which easily release their hydrogen aspositively-charged atoms or protons H⁺: SO₃H->SO₃ ⁻+H⁺

These ionic or charged forms allow water to penetrate into the membranestructure but not the product gases, namely molecular hydrogen H₂ andoxygen O₂. The resulting hydrated proton, H₃O⁺, is free to move whereasthe sulphonate ion SO₃ ⁻ remains fixed to the polymer side-chain. Thus,when an electric field is applied across the membrane 43 the hydratedprotons are attracted to the negatively charged electrode, known as thecathode 41 b. Since a moving charge is identical with electric current,the membrane 43 acts as a conductor of electricity. It is said to be aprotonic conductor.

A typical membrane material that is used is called “nafion”. Nafion is aperfluorinated polymer that contains small proportions of sulfonic orcarboxylic ionic functional groups.

Accordingly, as shown in FIG. 3, water, H2O, enters the cell and issplit at the surface of the membrane 43 to form protons, electrons andgaseous oxygen. The gaseous oxygen leaves the cell while the protonsmove through the membrane 43 under the influence of the applied electricfield and electrons move through the external circuit 44. The protonsand electrons combine at the opposite surface, namely the negativelycharged electrode, known as the cathode 41 b, to form pure gaseoushydrogen.

During operation of the fuel cell 5, a small amount of water, hydrogengas bubbles 22 and oxygen gas bubbles 23 emerge from the hydrogen outlet12 and oxygen outlet 13, respectively, of the fuel cell 5, and flow intothe hydrogen side 18 and oxygen side 19 of the tank 6. The bubbles risethru the water to upper air cavities 24 formed by the water level in thetank and the tank divider 17. The hydrogen and oxygen gas are keptseparate from each other in the upper cavities 24 by the divider 17 andwater level in the tank. As the hydrogen gas and oxygen gas fill theirrespective upper cavities 24, the gas flows out of the upper cavitiesthru fittings 25 in the case of hydrogen, and fitting 26, in the case ofoxygen on the upper side of the tank. The hydrogen gas flows thru tube27 connected to hydrogen fitting 28 of the housing unit 2. The oxygenflows thru tube 29 connected to fitting 30 of the housing unit 2.

As shown in FIG. 2, a vehicle 31 powered by a gasoline or diesel engine32 is equipped with the portable hydrogen supplemental system 1. Poweris supplied to the portable hydrogen supplemental system 1 by a vehiclebattery 33 connected to electrical wires 34. The electrical circuit tothe Hydrogen supplemental system includes a vacuum switch 35, or otherengine sensor and an operator controlled switch 36 which completes theelectrical circuit to the portable hydrogen generator system 1 when theengine is running. Once power is supplied to the portable hydrogensupplemental system 1, hydrogen gas flows thru hydrogen outlet tube 37connected to hydrogen fitting 28 of the housing unit 2 to an air intake38 of the vehicle's engine 32. Oxygen gas flows thru oxygen outlet tube39 and, in the case of gasoline engines with oxygen sensors, is ventedto the atmosphere. The two gasses can optionally be combined for dieselengine vehicles or other internal combustion engines without oxygensensors.

An alternative embodiment of the water tank 6 is illustrated in FIG. 4.As per the water tank 6 as shown in FIG. 4 dividers 17 a and 17 b areprovided at opposite ends of the tank so as to divide the tank 6 into ahydrogen section 18 and an oxygen section 19. Each divider 17 a,b isformed along the inner wall of the tank 6 and extends to approximately¼″ from the bottom surface 20 of the tank 6. As water is placed into thetank 6, the tank fills evenly on both sides of each of the dividers 17 aand 17 b.

As described above according to the invention as the hydrogen gas andoxygen gas fill their respective upper cavities 24, the gas flows out ofthe upper cavities thru fitting 25 in the case of hydrogen, and fitting26, in the case of oxygen on the upper side of the tank. Alternativelythe fittings 25 and 26 can be replaced by gas collectors 45 and 46. Eachgas collector 45, 46 is constructed to contain baffles 47 a and 47 bthat serve to prevent water from splashing into or entering the tubes 27and 29. Each baffle 47 a,b is configured to extend perpendicularly froman inner surface of the gas collectors 45 and 46. Particularly, baffle47 a is configured to extend from a portion of the inner surface of agas collector 45, 46 opposite to another portion of the inner surface ofthe gas collector 45, 46 from which baffle 47 b extends.

An alternative embodiment of the mounting bracket 3 is illustrated inFIGS. 5A-B. The mounting bracket 3 has formed therein oblong holes 48positioned near the corners of the mounting bracket 3 for receivingscrews/studs disposed on the undersigned of the housing unit 2. Theoblong holes 48 upon receiving the screws/studs disposed on theundersigned of the housing unit 2 allows for the housing unit 2 to beremovably attached to the mounting bracket 3. The housing unit 2 beingremovable from the mounting bracket 3 permits the user to remove theapparatus for servicing including adding water, performing repairs,exchanging parts, and the like.

The electrical circuit can, for example, be provided by a controlcircuit 50 as illustrated in FIG. 6 for controlling the Hydrogensupplemental system. The control circuit 50 includes a vacuum switch 35,or other engine sensor, that provides a positive output when the engineis operating, an operator controlled switch 36 which provides thepositive output from the vacuum switch 35 when the operator controlledswitch 36 is moved to the on position, a global positioning system (GPS)51 which provides a positive output when the speed of the automobileexceeds a predetermined level, AND gate 52, or other such circuitry,that provides a positive output when both the operator controlled switch36 and the GPS 51 outputs are positive, and a switch 53 which switcheselectrical power to the fuel cell 5 when the AND gate 52 supplies apositive output, thereby causing the fuel cell 5 to operate when theengine is operating and the speed of the automobile exceeds apredetermined level.

The Hydrogen supplemental system operates optimally in a gasolinepowered engine when the load on the engine does not exceed apredetermined level and the amount of hydrogen produced by the Hydrogensupplemental system and supplied to the gasoline powered engine fallswithin a preset range.

In a gasoline powered engine the electrical power used by the Hydrogensupplemental system is supplied by the engine alternator. As describedabove the electrical power is only supplied when the engine is operatingand the speed of the automobile exceeds a predetermined level. Thus, theload placed on the engine by the Hydrogen supplemental system is relatedto the amount of electrical power drawn from the alternator as measuredin amps. Optimally the Hydrogen supplemental system works best on agasoline powered engine when the load on the engine does not exceed acurrent of 4 amps being drawn from the alternator, or if measuredanother way of 56 watts. It should be noted that the amount of amps orwatts is dependent upon the size of the engine and alternator (four, sixor eight cylinders, etc.). It should also be noted that diesel engineshave a different optimal load setting.

Further, in a gasoline powered engine the optimal amount of hydrogenproduced by the Hydrogen supplemental system and supplied to thegasoline powered engine falls within a preset range of 0.10-0.25 litersper minute.

Based on the above a gasoline powered automobile achieves the highestlevel of fuel efficiency measured in miles/gallon of gas when the loadon the engine does not exceed 4 amps, or if measured another way of 56watts, and the amount of hydrogen produced and supplied to the gasolinepowered engine falls within a preset range of 0.10-0.25 liters perminute.

While the invention has been described in terms of its preferredembodiments, it should be understood that numerous modifications may bemade thereto without departing from the spirit and scope of the presentinvention. It is intended that all such modifications fall within thescope of the appended claims.

What is claimed is:
 1. A portable hydrogen supplemental system forsupplying hydrogen gas to an internal combustion engine comprising: ahousing unit; a fuel cell mounted inside the housing unit that convertswater into hydrogen and oxygen gas; a water tank mounted inside thehousing unit and positioned to supply water to the fuel cell; a powersupply for supplying electrical power to the fuel cell; an engine sensorfor detecting operation of the internal combustion engine and; anoperator control switch, wherein the water tank includes at least onetank divider which separates the water tank into at least two sectionsthat are both filled with water when water is placed into the watertank; wherein the water tank includes at least first and second gascollection cavities at a top portion thereof for collecting hydrogen andoxygen gas respectively, the gas collection cavities being formed by atop surface of the water tank, the tank divider and the water level inthe water tank; wherein each gas collection cavity includes a fitting atthe top thereof for distributing one of the hydrogen and oxygen gas outof the water tank; wherein the power supply supplies electrical power tothe fuel cell when the engine sensor detects that the internalcombustion engine is in operation and the operator control switch isactivated; wherein the fuel cell, when supplied with electrical power,produces hydrogen and oxygen gases from the water being supplied to thefuel cell, said hydrogen and oxygen gases being directed through thewater tank into the gas collection cavities at the top thereof forproper distribution of the gases such that the hydrogen gas is suppliedto the internal combustion engine for combustion therein; wherein thewater tank includes first and second dividers provided at opposite endsof the tank to divide the tank into a hydrogen section and an oxygensection; and wherein each divider is formed along an inner wall of thewater tank and extends to a predetermined position from the bottomsurface of the water tank such that when water is placed into the watertank, the water tank fills evenly on both sides of each of the dividers.2. A portable hydrogen supplemental system according to claim 1, furthercomprising: a mounting bracket which mounts the portable hydrogensupplemental system to a surface of the vehicle which includes theinternal combustion engine.
 3. A portable hydrogen supplemental systemaccording to claim 1, wherein the water tank is positioned above thefuel cell.
 4. A portable hydrogen supplemental system according to claim1, further comprising: a control electrical circuit, having a switch,which supplies electrical power to the fuel cell when the engine sensordetects that the internal combustion engine is in operation.
 5. Aportable hydrogen supplemental system according to claim 1, wherein saidfuel cell comprises: a plurality of layers, and wherein the electricalpower is applied to opposing layers of said fuel cell in a manner toproduce hydrogen and oxygen gases.
 6. A portable hydrogen supplementalsystem according to claim 1, wherein said the water tank comprises: awater supply fitting positioned on the underside of the water tankconnected to a tube that is connected to water inlet fitting on the fuelcell, wherein water is supplied to the fuel cell by the tube, andwherein the fuel cell further includes a hydrogen gas outlet fitting andan oxygen gas outlet fitting which are connected by other tubes to gasinlet fittings on the underside of the water tank.
 7. A portablehydrogen supplemental system according to claim 6, wherein duringoperation of the fuel cell, a small amount of water, hydrogen gasbubbles and oxygen gas bubbles emerge from a hydrogen outlet and anoxygen outlet, respectively, of the fuel cell, and flow into a hydrogenside and an oxygen side of the water tank, wherein bubbles rise throughthe water to the upper air cavities formed by the water level in thetank and the tank dividers such that hydrogen and oxygen gases are keptseparate from each other in the upper cavities by the dividers, andwherein as hydrogen gas and oxygen gas fill their respective uppercavities, gases flow out of the upper cavities through a hydrogenfitting and an oxygen fitting.
 8. A portable hydrogen supplementalsystem according to claim 7, wherein the hydrogen and oxygen fittingscan each be replaced by a gas collector which is constructed to containbaffles that serve to prevent water from splashing into or entering thetubes.
 9. A portable hydrogen supplemental system according to claim 8,wherein each baffle is configured to extend perpendicularly from aninner surface of the gas collector, and wherein a first baffle isconfigured to extend from a portion of the inner surface of the gascollector opposite to another portion of the inner surface of the gascollector from which a second baffle extends.
 10. A method of supplyinghydrogen gas to an internal combustion engine comprising: converting, bya fuel cell mounted inside a housing unit, water into hydrogen andoxygen gas; supplying, by a water tank mounted inside the housing unit,water to the fuel cell; detecting, by an engine sensor, operation of theinternal combustion engine; supplying, by a power supply, electricalpower to the fuel cell upon detecting that the internal combustionengine is in operation and an operator control switch is activated;producing, by the fuel cell, when supplied with the electrical power,hydrogen and oxygen gases from the water being supplied to the fuelcell, said hydrogen and oxygen gases being directed through the watertank into respective gas collection cavities at the top of the watertank for proper distribution of the gases; and supplying the hydrogengas to the internal combustion engine for combustion therein, whereinthe water tank includes at least one tank divider which separates thewater tank into at least two sections that are both filled with waterwhen water is placed into the water tank, wherein each gas collectioncavity includes a fitting at the top thereof for distributing one of thehydrogen and oxygen gas out of the water tank, wherein the water tankincludes first and second dividers provided at opposite ends of the tankto divide the tank into a hydrogen section and an oxygen section, andwherein each divider is formed along an inner wall of the water tank andextends to a predetermined position from the bottom surface of the watertank such that when water is placed into the water tank, the water tankfills evenly on both sides of each of the dividers.
 11. A methodaccording to claim 10, wherein a mounting bracket mounts the portablehydrogen supplemental system to a surface of the vehicle which includesthe internal combustion engine.
 12. A method according to claim 10,wherein the water tank is positioned above the fuel cell.
 13. A methodaccording to claim 10, wherein a control electrical circuit, having aswitch, supplies electrical power to the fuel cell when the enginesensor detects that the internal combustion engine is in operation. 14.A method according to claim 10, wherein said fuel cell comprises: aplurality of layers, and wherein the electrical power is applied toopposing layers of said fuel cell in a manner to produce hydrogen andoxygen gases.
 15. A method according to claim 10, wherein said the watertank comprises: a water supply fitting positioned on the underside ofthe water tank connected to a tube that is connected to water inletfitting on the fuel cell, wherein water is supplied to the fuel cell bythe tube, and wherein the fuel cell further includes a hydrogen gasoutlet fitting and an oxygen gas outlet fitting which are connected byother tubes to gas inlet fittings on the underside of the water tank.16. A method according to claim 15, wherein during operation of the fuelcell, a small amount of water, hydrogen gas bubbles and oxygen gasbubbles emerge from a hydrogen outlet and an oxygen outlet,respectively, of the fuel cell, and flow into a hydrogen side and anoxygen side of the water tank, wherein bubbles rise through the water tothe upper air cavities formed by the water level in the tank and thetank dividers such that hydrogen and oxygen gases are kept separate fromeach other in the upper cavities by the dividers, and wherein ashydrogen gas and oxygen gas fill their respective upper cavities, gasesflow out of the upper cavities through a hydrogen fitting and an oxygenfitting.
 17. A method according to claim 16, wherein the hydrogen andoxygen fittings can each be replaced by a gas collector which isconstructed to contain baffles that serve to prevent water fromsplashing into or entering the tubes.
 18. A method according to claim17, wherein each baffle is configured to extend perpendicularly from aninner surface of the gas collector, and wherein a first baffle isconfigured to extend from a portion of the inner surface of the gascollector opposite to another portion of the inner surface of the gascollector from which a second baffle extends.